Connector Protrusions Prevent Contact Deformation
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Solution Overview
Problem
The existing connector configurations suffer from poor mating operability and deformation/damage of pin and socket contacts due to gaps between pin contacts, allowing socket contacts and receptacle insulator corners to fit between them during mating.
Innovation Solution
A plug with an insulator featuring protrusions between aligned pin contacts and a receptacle with a spring portion that absorbs displacement, ensuring stable contact force and preventing deformation, with the spring portion positioned to avoid interference with pin contacts during mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pin contacts are aligned with gaps interposed therebetween, then the plug structure is simplified and easier to manufacture, but socket contacts and receptacle insulator corners fit between pin contacts during mating, causing poor mating operability and contact deformation
Solution Approach 1:
A protrusion is introduced as an intermediary element between adjacent pin contacts. This protrusion fills the gap between pin contacts and prevents socket contacts and receptacle insulator corners from fitting between them during mating operations, thereby improving mating operability while maintaining the aligned configuration of pin contacts
2Device complexity
If pin contacts are aligned with gaps interposed therebetween, then the plug structure is simpler, but pin contacts and socket contacts are deformed or damaged during mating
Solution Approach 1:
The protrusion acts as a protective intermediary that prevents direct contact and potential damage between socket contacts and the corners of receptacle insulators. By filling the gaps between pin contacts, it eliminates the harmful interaction that causes deformation and damage, thereby improving contact integrity without significantly increasing device complexity
3Reliability
If the spring portion is positioned to absorb displacement, then contact force stability is improved, but the spring portion may interfere with pin contacts during mating
Solution Approach 1:
The spring portion is strategically positioned in a specific location where it can absorb displacement and maintain contact force stability without interfering with pin contacts during mating operations. This localized positioning ensures that the spring's displacement-absorbing function is achieved while avoiding harmful interactions with other components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances mating operability and prevents deformation and damage of contacts by eliminating gaps between pin contacts and ensuring stable contact force through the spring portion's displacement absorption.
Implementation Method 1
The spring portion renders the contact portion displaceable in a direction parallel to the opposing direction with respect to the fixing portion
Data Source
AI summary
A plug for mating with a receptacle includes: an insulator that has an inner bottom surface, which is orthogonal to a mating direction of the plug; and a plurality of pin contacts secured to the insulator and aligned in an alignment direction, each of which includes a contact tab having a pair of planar surfaces of the contact tab on two mutually opposite sides thereof which are parallel to each other, the planar surface of the contact tab each forming a contact surface. The contact tabs stand up from the inner bottom surface in the mating direction, the contact surfaces being parallel to the alignment direction. A plurality of protrusions are formed in the insulator that stand up from the inner bottom surface in the mating direction, such that each of the protrusions is positioned between two of the contact tabs which are next to each other in the alignment direction.